Flat-Pack Insulated Shipping Container With Hinged Wall Assembly
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Solution Overview
Problem
Passive thermally insulated shipping containers require complex assembly and increased pack-out times due to numerous components, which can lead to errors and inefficiencies, especially in larger sizes, and are not easily handled or stacked, increasing costs and the risk of temperature excursions during shipment.
Innovation Solution
A thermally insulated shipping container design featuring hinged side outer walls that form a U-shaped configuration for self-support during assembly, reducing the number of components to unpack and assemble, allowing for easier handling and stacking, and utilizing a robust structure to maintain thermal integrity during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If passive shippers are delivered flat packed to reduce in-bound delivery costs, then storage and transport efficiency are improved, but pack out times are significantly increased
Solution Approach 1:
The outer wall is divided into multiple panels that can be folded flat for storage and transport, yet quickly assembled into a three-dimensional structure during pack out. The hinge connections allow individual panels to be segmented for compact storage but reassembled rapidly when needed, resolving the contradiction between storage efficiency and assembly speed.
Solution Approach 2:
The hinge mechanism transforms the rigid outer wall into a dynamic structure that can transition between flat-packed and three-dimensional states. This dynamic capability allows the same structure to optimize for storage efficiency during transport and for rapid assembly during pack out, eliminating the need to choose between conflicting requirements.
2Reliability
If numerous components are used in passive shippers to ensure thermal insulation, then thermal integrity is improved, but assembly complexity and error risk are increased
Solution Approach 1:
Multiple outer wall panels are merged into a single hinged assembly unit that functions as one integrated component during storage and transport. This merging reduces the number of separate parts that need to be handled and assembled, simplifying the assembly process while maintaining the thermal insulation properties of all panels.
Solution Approach 2:
The hinged outer wall structure is designed to self-assemble into its three-dimensional configuration without requiring complex fastening operations or multiple workers. The hinge mechanism automatically guides the panels into their correct positions, reducing assembly complexity and minimizing the risk of errors while preserving thermal integrity.
3Strength
If traditional rigid structures are used for shippers, then structural strength is improved, but handling and stacking difficulty are increased
Solution Approach 1:
The rigid outer wall is transformed into a dynamic hinged structure that can flex during handling and stacking operations, then lock into a rigid three-dimensional form when assembled. This dynamic capability allows the structure to adapt to handling requirements while maintaining the structural strength needed for thermal protection during shipment.
Solution Approach 2:
The structural parameters of the outer wall change based on its state: in the flat-packed configuration, the structure is flexible and easy to handle; when assembled, the hinge connections create a rigid structure with sufficient strength for thermal integrity. This parameter change resolves the contradiction between handling ease and structural strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design significantly reduces assembly time and errors, enhances handling and stacking capabilities, and maintains thermal integrity, making the container more reliable and cost-effective for shipping temperature-sensitive products.
Implementation Method 1
a portion of each of the two side outer walls is hinged at one end to a respective end of one of the front or rear outer walls
Implementation Method 2
a cavity extending at least between the inner and outer walls arranged to receive a plurality of cool packs
Data Source
AI summary
A thermally insulated shipping container comprises an inner structure including an inner base, a front inner wall, a rear inner wall opposed to the front inner wall, a pair of opposed side inner walls each extending between the front and rear inner walls and an inner lid; an outer structure including an outer base, a front outer wall, a rear outer wall opposed to the front inner wall, two side outer walls each extending between the front and rear outer walls and an outer lid; and a cavity extending at least between the inner and outer walls, the cavity being arranged to receive a plurality of cool packs; wherein the container, when empty, is arranged to be transported disassembled in a flat packed state prior to being assembled for use.